Aviation
Aviation
The aerospace industry was one of the earliest to fully adopt thermal spray coatings, which today are indispensable for modern aircraft engines. In fact, hundreds of critical engine components rely on these coatings to achieve optimal performance. Without them, turbines would suffer premature wear and reduced efficiency.
Aircraft engines face severe degradation challenges, including metal-to-metal wear, fretting, hot corrosion, particle erosion, and other high-temperature damages. Thermal spray coatings provide the necessary protection, extending component life and ensuring safe, reliable operations under extreme conditions.
At TSS, we deliver advanced thermal barrier coatings, oxidation and corrosion protection, and wear-resistant solutions designed to withstand both low- and high-temperature stresses. By combining plasma spray, HVOF, and other cutting-edge techniques, we help aerospace manufacturers and MROs maximize performance, reduce downtime, and improve safety.
Typical aerospace components treated with TSS thermal spray coatings include:
Turbine blades
Flame tubes
HPT outer stationary seal liners
Compressor and fan components
Bearings and accessories
Afterburner elements
Application challenges and solutions:
Table
Thermal barrier
Tip clearance
thermal spray thermal barrier coating using plasma spray
Abradable coating using plasma spray
Lubricity
Lubricity coatings applied using plasma spray
Other contents
Corrosion can significantly compromise the performance and durability of structural components if left unprotected.
In the aerospace industry, corrosion may cause pitting that jeopardises the mechanical integrity of rotating compressor blades and vanes. Additionally, corrosion and oxidation can roughen the gas-washed surfaces of airfoils, increasing aerodynamic drag and reducing compressor efficiency.
Protective thermal spray coatings provide an effective solution, extending component lifespan, maintaining optimal aerodynamic performance, and ensuring reliable operation under demanding conditions.
Erosion refers to the gradual loss of material from a solid surface due to mechanical interaction with fluids or solid particles. It typically occurs when solid particles or water droplets impact critical surfaces at high velocity.
In aero gas turbines, for example, sand and particulate erosion in compressors can lead to a reduction in compression ratio, negatively affecting overall engine efficiency and performance.
Thermal spray coatings offer an effective solution, protecting compressor blades, vanes, and other critical components from erosion, preserving aerodynamic efficiency and extending service life.
Galling is a severe form of wear, defined by ASTM G40 as “surface damage occurring between sliding solids, characterised by microscopic, often localised roughening and the formation of protrusions above the original surface.”
It occurs when two surfaces slide under load, causing movement and plastic deformation that can transfer material from one surface to another.
In aerospace components such as turbine blades and vanes, galling can significantly increase maintenance and repair costs, reduce component lifespan, and compromise engine reliability.
Protective thermal spray coatings, applied using HVOF or plasma technologies, minimise galling by reducing friction and enhancing surface hardness, ensuring longer-lasting, high-performance components.
Components operating in high-temperature environments require reliable thermal protection to maintain performance and ensure durability. At TSS Surface Technologies, we provide advanced thermal protective coatings designed to extend the operational life of critical aerospace components.
In the aviation industry, turbine blades are routinely exposed to temperatures of up to 1,650°C, far exceeding the melting points of common high-temperature structural materials, such as superalloys with a melting point around 1,300°C.
Without proper thermal protection, these extreme conditions can cause severe oxidation and hot corrosion of combustor and basket components. Unprotected blades and vanes lose load-carrying capacity, as elevated temperatures reduce the mechanical strength of structural materials, jeopardising engine efficiency and reliability.
Thermal spray coatings provide a robust solution, enhancing resistance to oxidation, hot corrosion, and thermal fatigue, while ensuring turbine components maintain their structural integrity and long-term operational performance.
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